Desk and chair set

ABSTRACT

A desk assembly and method of manufacturing the desk assembly. The desk assembly includes a frame supporting a top assembly. The frame includes two or more leg portions telescopically coupled to one another such that the top assembly is height adjustable. The top assembly is formed from a plastic molded base bonded to a high pressure laminate sheet to form a seamless panel. The seamless panel is straighted from a deformed state during the manufacturing process to a flat surface by adhering the panel to a substrate with adhesive and pressure. The top assembly may include an angled portion set off by a flowing arc to increase user comfort. The desk assembly may include a chair assembly integrally formed with the frame and one or more semi-transparent modesty panels.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a divisional application of U.S. patent application Ser. No.11/443,526, filed May 30, 2006, which claims the benefit of U.S.Provisional Patent Application No. 60/685,641, filed May 27, 2005, theentirety of which is hereby incorporated by reference.

TECHNICAL FIELD

The present invention relates to a desk and chair set and moreparticularly to a student desk and chair set with a seamless durable topsurface.

BACKGROUND

School desk and chair combinations are often not sufficiently durable.Many desk tops are made with high pressure laminate adhered to particleboard where edges are covered with a “T-molding” or other edgebordering. These laminated desk tops often fail by separating, usuallywith the help of desk users who might pick at any visible seam betweendesk parts or layers.

SUMMARY

In one embodiment, the present invention is a desk assembly including adesk frame having two or more leg portions and a top assembly supportedby the desk frame. The top assembly is seamless and is formed of aplastic molded base bonded to a high pressure laminate sheet. Asubstrate is adhered to the plastic molded base and high pressurelaminate sheet and may be one of molded wood, particle board or plywood.The top assembly may be height adjustable with the leg portionstelescopically coupled to one another. The top assembly provides aseamless desk surface to reduce separation failures.

In another embodiment, the present invention is a desk assemblyincluding a desk frame having two or more leg portions and a topassembly supported by the frame. The top assembly includes a top surfaceformed with a forward edge and an angled portion set off from theforward edge by a flowing arc. The angled portion slopes at an angle offrom about 16°0 to about 20°. At a center of the forward edge of the topsurface, the angled portion extends for about two inches from theforward edge to the flowing arc. The angled portion provides an easedportion for the user's comfort.

In another embodiment, the present invention is a method of forming atop assembly for a desk set. A high pressure laminate sheet is insertedinto one side of an injection mold. The high pressure sheet is held inplace by a series of vacuum ports. ABS plastic is molded around the highpressure laminate sheet to bond the high pressure laminate sheet to theABS plastic. Because the two different materials have different shrinkrates, the resulting panel is initially deformed. The seamless panel isthen straightened and connected to a desk frame. The seamless panel isstraightened by adhering the panel to a substrate with adhesive andpressure. The substrate may be one of molded wood, particle board orplywood.

While multiple embodiments are disclosed, still other embodiments of thepresent invention will become apparent to those skilled in the art fromthe following detailed description, which shows and describesillustrative embodiments of the invention. Accordingly, the drawings anddetailed description are to be regarded as illustrative in nature andnot restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a desk and chair set.

FIG. 2 is an enlarged downward looking isometric view of the desk shownin FIG. 1.

FIG. 3 is an upward looking isometric view of the desk shown in FIG. 2.

FIG. 4 is an enlarged downward looking isometric view of the chair shownin FIG. 1.

FIG. 5 is an upward looking isometric view of the chair shown in FIG. 4.

FIG. 6 is a bottom plan view of the chair shown in FIGS. 4 and 5.

FIG. 7 is a downward looking isometric view of another embodiment of adesk and chair set.

FIG. 8 is an upward looking isometric view of the desk and chair setshown in FIG. 7.

FIG. 9 is an enlarged exploded isometric view of a portion of a toppanel of a top assembly of the desk shown in FIGS. 1-3, 7 and 8.

FIG. 10 is an exploded view of the top assembly of the desk.

FIG. 11 is an isometric view of the top assembly of the desk.

FIG. 12 is a downward looking isometric view of a frame for the desk.

FIG. 13 is a side elevation view of the frame for the desk.

FIG. 14 is a rear elevation view of the frame for the desk.

FIG. 15 is a rear elevation view of the desk.

FIG. 16 is an enlarged sectional view taken along line 16-16 of FIG. 15.

FIG. 17 is a brief flow chart of a process for forming the top assemblyof the desk.

FIG. 18 is a downward looking isometric view of a book box assembly forthe desks of FIGS. 1-3, 7 and 8.

FIG. 19 is an isometric view of a modesty panel for the desks of FIGS.1-3, 7 and 8.

FIG. 20 is an isometric view of the desk shown in FIGS. 1-3 with anattached book box assembly and modesty panel.

While the invention is amenable to various modifications and alternativeforms, specific embodiments have been shown by way of example in thedrawings and are described in detail below. The intention, however, isnot to limit the invention to the particular embodiments described. Onthe contrary, the invention is intended to cover all modifications,equivalents, and alternatives failing within the scope of the inventionas defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

The present invention, in one embodiment, relates to a desk and chairset 10, shown in FIG. 1, of the type used by school children. The setincludes a desk assembly 12 and a chair assembly 14. The desk and chairset is simply constructed, robust, durable, aesthetically pleasing andyet moderately priced. The writing or top surface 16 of the deskassembly is seamless so as to minimize separation failures common tostudent desks.

Referring now to FIGS. 2 and 3, the desk assembly 12 includes a topassembly 20, a frame 22 and four plastic glides 24, 26, 28, 30. The topassembly 20 includes the generally flat top surface 16 with an angled oreased edge portion 34 set off by a flowing arc 36 to enhance comfort fora desk user. The desk does not include sharp corners at the userinterface so as to avoid increased pressure on the user's forearm area.

The desk frame 22 includes two leg portions 40, 42, a cross bar portion44 and two runner portions 46, 48. The desk frame may be made of tubularsteel or other suitable material and the cross bar portion 44 may bewelded to the leg portions 40, 42.

The desk assembly 12 is height adjustable by virtue of openings 50, 52,54 vertically aligned on the desk frame leg portion 42 and similaropenings in the leg portion 40 (not shown) which enable the receipt offasteners as will be explained below. The desk assembly may come indifferent sizes as either or both the frame and the top assembly may bescaled up or down as a function of the size of children expected to usethe desk and chair set.

The chair assembly 14 shown in detail in FIGS. 4, 5 and 6 and mayinclude a molded plastic shell 60 in which a back portion 62 and a seatportion 64 are integrally formed. An opening 66 may be provided betweenthe back portion and the seat portion. The shell is mounted to a chairframe 68 and four plastic guides 70, 72, 74, 76 are attached to thechair frame.

The chair frame 68 may be formed of steel tubing of the same type anddimension as the desk tubing and may include an inverted U-shaped backportion 80, a generally U-shaped seat portion 82, two rear leg portions84, 86 and two runner portions 88, 90 to which the glides 70, 72, 74, 76are affixed. The shell 60 is attached to the frame in any convenientfashion, such as threaded fasteners 92, 94 attaching the back portion 80of the chair frame to the back portion 62 of the shell 60. A second pairof threaded fasteners 96, 98 may attach the front of the seat portion 82of the chair frame to the seat portion 64 of the shell 60 and a group ofrivets 100, 102, 104, 106 may be used to connect a pair of integralshell flanges 110, 112 with the seat portion 82 of the chair frame 68.It is to be noted that the chair assembly may be scaled up or down as afunction of the size of the expected user.

Another embodiment of a desk and chair set 116 is shown in FIGS. 7 and8. The connected set includes an integral frame 118, a chair shell 120that may be identical to the shell 60 of the chair assembly 14illustrated in FIGS. 4-6 and a top assembly 122 that may be identical tothe top assembly 20 illustrated in FIGS. 2 and 3. Connecting the chairshell 120 and the top assembly 122 is the frame 118 in which the deskand chair share common runner portions 126, 128 of the frame 118. Thechair and desk runners are integral such that the distance between thechair shell 120 and the top assembly 122 is fixed. The remainder of thechair frame 118 including a back portion 130, a seat portion 132 and tworear leg portions 134, 136 may be identical to the chair frame 68described in relation to FIGS. 4-6, and two leg portions 140, 142 and across bar portion 144 of the desk set 116 may be identical to the legportions 40, 42 and the cross bar portion 44 described in relation tothe desk frame 22 shown in FIGS. 2 and 3.

Plastic guides 150, 152, 154, 156 may be attached to the frame 118 atthe lower corners as shown. The size of the desk and chair set 116 maybe scaled up or down as a function of the size of the expected user.

In FIG. 9 a portion of the desk top assembly 20 is illustrated andincludes a high pressure laminate sheet (“HPL”) 160 and a plastic moldedbase 162 to form a durable, bonded panel 163. The panel is created in aninjection molding machine well known to those skilled in the art. Thehigh pressure laminate 160 is placed on one side of the injection moldand is held in place by a series of vacuum ports. Plastic is theninjected and molded to the back of the HPL sheet thereby bonding the twomaterials together. The plastic may be ABS and assumes the shape of thebase 162 in the mold. An indentation 164 is provided in the top surfaceof the base to accommodate the HPL sheet. Because two differentmaterials with different shrink rates are used, the resulting bondedpanel 163 is initially deformed when cooled.

The top assembly forming process continues by attaching the distortedbonded panel 163 of HPL and ABS to a substrate 165 using an adhesive andpressure or a combination of adhesive, pressure and mechanicalfasteners. This step straightens

The top assembly is completed by the addition of a pair of steelbrackets 170, 172 which include leg supports 174, 176, and a bottomcover 178 which includes support sleeves 180, 182. The brackets may beattached to the substrate 165 with any suitable fasteners such as screws190, 192, 194, 196 and the bottom cover 178 may be attached to thebonded HPL/ABS panel 163 using any suitable fasteners, such as screws200, 202, 204, 206, 208, 210, 212, 214, 216 which sandwiches thebrackets 170, 172 and the substrate 165 between the bottom cover 178 andthe bonded panel 163. The bottom cover 178 may be formed of ABS.

As mentioned above, the desk top assembly 20 is height adjustable usingthe openings 50, 52, 54 in the desk frame as well as openings in thesupports, such as the openings 220, 222, 224 in the support 174, wherebyfasteners passing through the aligned openings of the desk frame and thesupports fix the top assembly at a desired predetermined verticalelevation. Openings are also formed in the support 176 but are notvisible in FIGS. 10 and 11.

Referring now to FIGS. 12-14, the desk frame 22 is shown in more detailand includes the two leg portions 40, 42, the cross bar portion 44 andthe runner portions 46, 48. At the upper ends of each of the legportions, there are the series of openings, such as the openings 50, 52,54, enabling the top assembly 20 to be vertically adjustable in relationto the desk frame 22.

In one version of the desk frame, the width of the leg portions isapproximately 23 inches, the width of the runners is approximately 26inches and the height of the desk frame is approximately 22 inches. Thecross bar portion may be located approximately 10 inches from the top ofthe frame and the frame may have an angular disposition between therunner portions and the leg portions of about 77 degrees. As mentioned,it is to be understood that the desk frame may be built in smaller orlarger versions as a function of the size of the people expected to beusing the desk, and the desk frame as well as the chair frame may have achrome or powder coat or any other suitable finish.

A complete desk may be seen in FIG. 15 including the desk frame 22 andthe top assembly 20. The supports 174, 176 have a smaller diameter thando the leg portions 40, 42 of the desk frame so that the supportstelescope downwardly into the leg portions. The interfaces between theupper supports and the lower leg portions are covered by the sleeves180, 182 thereby giving the aesthetically appealing appearance of thedesks shown in FIGS. 1-3, 7, 8 and 15. As mentioned above, both thesupports and the leg portions of the desk frame include verticallydisposed openings and by aligning the openings, fasteners, such as pinsor screws, may be inserted to allow vertical adjustment of the topassembly 20 relative to the desk frame 22 and relative to a floor uponwhich the desk is disposed.

Referring now to FIG. 16, there is illustrated in more detail the topassembly 20 which includes the bonded panel 163, consisting of the HPLsheet to which the ABS plastic is molded around so as to create themolded-in, seamless top surface 16, the backing substrate 165, and thebottom cover 178. The cover 178 and the panel 163 include bosses 230,232, 234, 236, 238, 240 to receive threaded fasteners, such as thescrews 206, 208, 210, for forming a durable, seamless, strong andrelatively inexpensive top assembly. These features make the topassembly especially well suited for school equipment applications.

The eased edge portion 34, FIGS. 2 and 16, slopes at an angle of about16-20 degrees, and preferably about 18 degrees, and at the center of thedesk the eased edge portion extends for about two inches from an edge242 to the arc 36. This feature provides superior comfort to thedesk/chair set user.

One embodiment of a process for forming the top assembly is brieflyillustrated in a flow diagram 250, FIG. 17, and may include the steps ofinserting 252 the high pressure laminate sheet into one side of aninjection mold, holding 254 the high pressure laminate sheet by a seriesof vacuum ports, molding the ABS plastic around the HPL sheet to bond tothe HPL sheet 160 to the ABS base 162, the molding step being designated256, using an adhesive and pressure to attach the substrate 165 to theseamless panel 163, this step being designated 258, fastening 260 thebottom cover 178 to the panel 163 and connecting 262 the top assembly 20to the desk frame 22.

In more detail the process of manufacturing and assembling of the deskis as follows. The HPL sheet having been routered to shape is placed ina holding fixture to ensure that the part is oriented in the properdirection. A linear positioning device picks the HPL sheet from a stackusing suction cups and vacuum. The linear positioning device verifiesthat the sheet is in place through the use of vacuum signal switches.The sheet is positioned above a mold until a preceding cycle iscompleted. The mold opens to full stroke and the linear positioningdevice descends with the HPL sheet to a programmed centered position.The sheet is moved to the mold surface by the linear positioning deviceand light pressure is applied until vacuum (reduced pressure) in themold, which is generated through vacuum pumps and applied through smallport holes in the mold surface, holds the sheet in position. When thevacuum level reaches a minimum of about 21 inches Hg, the linearpositioning device retracts. The linear positioning device then dropsdown approximately four inches and shifts to within one inch of theopposite mold face and begins generating vacuum in four suction cups onthat side of the mold. When in position the press ejects a part forwarduntil contact is made with the suction cups.

When a correct vacuum signal is received by the linear positioningdevice ejectors retract and the part is raised out of the mold where itis positioned until the mold closes and an injection unit fills thebalance of the cavity with ABS plastic. Through heat and pressure theHPL sheet bonds in place with the ABS to form the top panel 163. Whenmold closes the linear positioning device transports the panel out ofthe press area to a position above a conveyor belt. The panel descendsand rotates about 90 degrees and then is released to the conveyor beltwhere the panel is conveyed outside of a safety cage for finishingprocedures. The linear positioning device moves back into position abovethe HPL sheet stack. The cycle repeats. The panel is placed in a fixtureand clamped. Adhesive is applied to a bottom surface of the panel. Asubstrate is positioned onto the panel. A top clamp is closed andlocked. The panel/substrate combination remains clamped until theadhesive is cured. The bonded panel and substrate is then removed fromthe clamping station. The supports and bottom cover are attached withthreaded fasteners. The top assembly is connected to the desk frame.Beyond the specific steps mentioned above, standard molding techniques,equipment, temperatures and pressures as are known in the art are usedin the process. It is also to be noted that variations of the processsteps may be used without departing from the invention described herein.

Referring now to FIG. 18, there is illustrated a book box assembly 270having two side walls 272, 274, a back wall 276, a bottom wall 278 andan open front 280. Fasteners 282, 284, 286, 288, 290 may be used toconnect the book box assembly to the lower cover 178 and the substrate165 of the top assembly 20 to provide a student with a space for storingbooks, papers and school supplies. The book box assembly is made ofsemi-transparent molded thermoplastic such that light and objects arevisible. For example, the material may be styrene methyl methacrylatecopolymer sold under the brand ZYLAR 531 by the Nova Chemical Company ofCalgary, Alberta, Canada. The plastic may have a nominal thickness ofabout 0.125 inches and includes a texture identified as MT 11030 (MoldTech 11030). The product has a transmittance of about 89% and a haze ofabout 1.8%.

Referring to FIG. 19, there is illustrated a molded modesty panel 300having a center portion 302 and two end sleeves 304, 306 which allow thepanel to be snapped onto the leg portions 40, 42 of the desk frame 22. Adesk 310 having attached the book box assembly 270 and the modesty panel300 is illustrated in FIG. 20. The material of the modesty panel isfrosted polycarbonate sold under the Plexiglass brand having a nominalthickness of about 0.125 inches. As with the book box assembly, themodesty is semi-transparent having approximately the same translucencycharacteristics as the book box assembly. The advantage of havingsemi-transparent modesty panels and book box assemblies is that studentproperty may be monitored by school personnel.

Manufacture and assembly of the desk and chair sets are relatively easyand straightforward. Both frames for the desk and the chair are made oftubular steel which are cut and formed to the shapes shown in thedrawing. The chair shell is molded as one piece and connected to thechair frame. The desk top assembly is formed as described above toprovide a seamless bonded top panel and the top assembly is adjustablyconnected to the desk frame.

The material, dimensions and shapes described with respect to theembodiments generally shown in FIGS. 1-20 may be altered. For example,molded or machined wood, thermoplastics or other compositions may beused for the panel 163. The substrate 165 may be formed of wood, woodproduct board, thermoplastic composition or other suitable material.There are also many thermoplastics that may be textured of otherwiseformed to be semi-transparent.

Various modifications and additions can be made to the exemplaryembodiments discussed without departing from the scope of the presentinvention. For example, while the embodiments described above refer toparticular features, the scope of this invention also includesembodiments having different combinations of features and embodimentsthat do not include all of the described features. Accordingly, thescope of the present invention is intended to embrace all suchalternatives, modifications, and variations as fall within the scope ofthe claims, together with all equivalents thereof.

1. A desk assembly comprising: a desk frame including two or more legportions; and a top assembly supported by the desk frame, the topassembly formed of a plastic molded base bonded to a high pressurelaminate sheet.
 2. The desk assembly of claim 1 wherein the top assemblyfurther includes a substrate adhered to the plastic molded base and highpressure laminate sheet.
 3. The desk assembly of claim 2 wherein thesubstrate is one of molded wood, particle board or plywood.
 4. The deskassembly of claim 1 wherein the top assembly is seamless.
 5. The deskassembly of claim 1 wherein the top assembly is height adjustable. 6.The desk assembly of claim 5 wherein each leg portion includes an upperportion telescopically coupled to a lower portion.
 7. The desk assemblyof claim 1 wherein a forward edge of the top surface includes an angledportion set off by a flowing arc.
 8. The desk assembly of claim 1further comprising a chair assembly coupled to the desk frame.
 9. Thedesk assembly of claim 8 wherein the chair assembly includes a chairframe integrally formed with the desk frame.
 10. The desk assembly ofclaim 1 further comprising one or more semi-transparent panels coveringthe desk frame.
 11. A desk assembly comprising: a desk frame includingtwo or more leg portions; and a top assembly supported by the deskframe, the top assembly including a top surface formed with a forwardedge and an angled portion set off from the forward edge by a flowingarc.
 12. The desk assembly of claim 11 wherein the angled portion slopesat an angle of from about 16° to about 20°.
 13. The desk assembly ofclaim 11 wherein at a center of the forward edge of the top surface, theangled portion extends for about two inches from the forward edge to theflowing arc.
 14. The desk assembly of claim 11 wherein the top surfaceof the top assembly is seamless.
 15. The desk assembly of claim 11wherein the top assembly is formed of a plastic molded base bonded to ahigh pressure laminate sheet.